Assembly
Precaution1. All O-rings and gaskets must be replaced with the new ones included in the overhaul kit.
2. The bearing outer race and bearing inner race must be replaced as a unit.
3. Before assembly, make sure all parts are completely clean.
4. Assemble the parts within 10 minutes after applying sealant. Allow all sealant to cure at least 30 minutes after assembly before filling the transaxle with transaxle oil.
Primary Shaft Assembly and Secondary Shaft Assembly
1. Assemble in the order shown in the image, referring to Assembly Note.
1. Clutch hub
2. Synchronizer key
3. Clutch hub sleeve
4. Synchronizer spring
5. Clutch hub
6. Synchronizer key
7. Clutch hub sleeve (reverse gear)
8. Synchronizer spring
9. Primary shaft
10. Bearing inner race
11. 3rd gear
12. Synchronizer ring (3rd)
13. Clutch hub assembly (3rd/4th)
14. Retaining ring
15. Synchronizer ring (4th)
16. 4th gear
17. Bearing inner race
18. Secondary shaft
19. Bearing inner race
20. 1st gear
21. Synchronizer ring (1st)
22. Clutch hub assembly (1st/2nd)
23. Retaining ring
24. Synchronizer ring (2nd)
25. 2nd gear
26. Secondary 3rd gear
27. Retaining ring
28. Secondary 4th gear
29. Bearing inner race
30. Control rod
31. Control lever
32. Roll pin
33. 1st/2nd shift fork
34. Control end
35. Roll pin
36. Interlock sleeve
37. 3rd/4th shift fork
Assembly note
Clutch hub
NOTE: Synchronizer key dimensions are as follows.
1. Install the synchronizer key springs in the clutch hub with the hooks in the grooves to hold the three synchronizer keys in place.
Bearing inner race (primary shaft end)
1. Install the new bearing inner race with the SST.
NOTE: Press to 19,620 N (2,000 kg, 4,400 lb).
3rd gear, synchronizer ring (3rd) and clutch hub assembly (3rd/4th)
NOTE:
- The size of the 1st, 2nd, 3rd, and 4th synchronizer rings are the same. Be careful when installing them. The 2nd ring has the larger cut-out as shown in the illustration.
- Align the synchronizer ring groove and clutch housing hub key when installing.
1. Install the 3rd gear, synchronizer ring (3rd), and clutch hub assembly (3rd/4th) with the SST.
NOTE: Press to 19,620 N (2,000 kg, 4,400 lb).
Synchronizer ring (4th), 4th gear and bearing inner race
1. Install the synchronizer ring (4th), 4th gear, and bearing inner race with the SST.
NOTE: Press to 19,620 N (2,000 kg, 4,400 lb).
2. Measure the clearance between the 3rd gear and 2nd gear.
Clearance: 0.05 - 0.20 mm (0.002 - 0.008 in.)
Maximum: 0.25 mm (0.010 in.)
3. Measure the clearance between the 4th gear and bearing inner race.
Clearance: 0.165 - 0.365 mm (0.0064 - 0.0144 in.)
Maximum: 0.415 mm (0.0163 in.)
4. If not as specified, reassemble the primary shaft assembly.
Bearing inner race (secondary shaft end)
1. Install the new bearing inner race with the SST.
NOTE: Press to 19,620 N (2,000 kg, 4,400 lb).
1st gear, synchronizer ring (1st) and clutch hub assembly (1st/2nd)
NOTE: Align the synchronizer ring, groove and clutch housing hub key when installing.
1. Assemble the 1st gear, synchronizer ring (1st), and clutch hub assembly (1st/2nd), as shown in the image.
2. Press the clutch hub assembly (1st/2nd) on with the SST
NOTE: Press to 19,620 N (2,000 kg, 4,400 lb).
Synchronizer ring (2nd), 2nd gear and secondary 3rd gear
1. Install the synchronizer ring (2nd) and 2nd gear.
2. Install the secondary 3rd gear with the SST.
NOTE: Press to 19,620 N (2,000 kg, 4,400 lb).
Secondary 4th gear and bearing inner race
1. Install the secondary 4th gear and new bearing inner race.
2. Measure the clearance between the 1st gear and differential drive gear.
Clearance: 0.05 - 0.28 mm (0.002 - 0.011 in.)
Maximum: 0.505 mm (0.0199 in.)
3. Measure the clearance between the 2nd gear and secondary 3rd gear.
Clearance: 0.1 75 - 0.455 mm (0.0069 - 0.0179 in.)
Maximum: 0.505 mm (0.0199 in.)
4. If not as specified, reassemble the secondary shaft assembly.
Interlock sleeve
1. Install both shift forks and the interlock sleeve, as in the image.
Clutch Housing and Transaxle Case Components
1. Select the adjust shim(s), referring to Bearing Preload Adjustment.
2. Assemble in the order shown in the image, referring to Assembly Note.
3. Verify that the bearing preload is satisfied after assembly, referring to Bearing Preload.
Bearing preload adjustment
Adjust the bearing preload by selecting adjust shim(s).
1. Install the primary and secondary shaft bearing outer races into the transaxle case (diaphragm springs and shims removed).
2. Mount the clutch housing onto the transaxle hanger, and set the differential bearing outer race into the clutch housing. Position a piece of pipe against the outer race and tap in with a hammer until it contacts the clutch housing.
3. Set the outer races into the SST (selector) as shown in the image.
NOTE: Turn the selector to eliminate the gap Indicated by the arrow in the image.
4. Set the differential assembly into the clutch housing; then set the bearing outer race and the SST (selector) on the differential. Set the assembled selectors for the primary and secondary shaft in the clutch housing.
Mount the shaft gear assemblies as shown in the image.
5. Set the SST (collars) in the positions shown in the image.
6. Install the transaxle case and tighten the SST (bolts) to the specified torque.
Tightening torque: 37 - 52 N-m (3.8 - 5.3 m-kg, 27 - 38 ft-lb)
7. To seat the bearings, mount the SST (bars) on parts (A) and (B) of the selector, and turn the selector so the gaps are widened.
Then turn the SST in the reverse direction until the gaps are eliminated.
NOTE: Check that each shaft turns smoothly.
8. Manually expand the selector until it no longer turns by hand.
CAUTION: Measure the gap around the entire circumference of the selector.
9. Use a feeler gauge and measure the gap in the selector.
10. Take the maximum reading and determine the shim to be used as follows:
NOTE: Use a maximum of two shims.
< Primary shaft adjust shim >
- Subtract the diaphragm spring thickness (0.70 mm, 0.0276 in.) from the gap determined in Step 9.
- Select the closest thinner shim from the image.
Example
1 .22 mm (0.0480 in.) - 0.70 mm (0.0276 in.) = 0.52 mm (0.0204 in.)
Shim: 0.50 mm (0.020 in.)
< Secondary shaft adjust shim >
- Subtract the diaphragm spring thickness (0.70 mm, 0.0276 in.) from the gap determined in Step 9.
- Select the closest thicker shim from the image.
Example
1.22 mm (0.0480 in.) - 0.70 mm (0.0276 in.) = 0.52 mm (0.0204 in.)
Shim: 0.55 mm (0.022 in.)
11. Install the SST.
12. Adjust the selector with the SST until the specified preload is obtained.
Preload: 0.5 N-m (5 cm-kg, 4.3 in-lb)
CAUTION: Measure the gap around the entire circumference of the selector
13. Use a feeler gauge to measure the gap in the selector for the differential.
14. Add 0.15 mm (0.0059 in.) to the measured clearance and select the combination of shims closest in value to that measurement.
NOTE: Use a maximum of two shims.
See the image below for available shim sizes.
Example: 0.32 mm (0.013 in.)
0.32 mm (0.013 in.) + 0.15 mm (0.006 in.) = 0.47 mm (0.019 in.).
So the nearest shim (on the thick side) to 0.47 mm (0.019 in.) is 0.50 mm (0.020 in.).
15. Remove the SST and the transaxle case.
16. Remove the selectors, the primary shaft assembly and the differential.
17. Remove the bearing outer races.
Assembly note
Oil seals
1. Apply transaxle oil to outer periphery.
2. Install the new oil seals with the SST.
Diaphragm spring
1. Install the diaphragm spring as shown in the image.
Boot
1. Install the boot with the drain hole facing downward.
Bearing preload
Verify the shaft gears and the differential bearing preload.
NOTE:
- Verify that the correct adjust shims were selected.
- If the bearing preload is not within specification, adjust again.
1. Set the primary shaft gear and the differential into the clutch housing.
2. Install the transaxle case, and tighten to the specified torque.
Tightening torque: 37 - 52 N-m (3.8 - 5.3 m-kg, 27 - 38 ft-lb)
3. Connect the SST and install it through the driveshaft hole.
4. Hook a spring scale to the attachment and measure the preload.
Preload: 1.4 - 2.0 N-m (14 - 20 cm-kg, 12 - 17 in-lb)
5. Remove the SST.
6. With the transaxle facing in the direction shown in the image, install the SST to the primary shaft gear.
7. Measure the preload.
Preload: 0.1 - 0.25 N-m (1.0 - 2.5 cm-kg, 0.87 - 2.18 in-lb)
8. Remove the SST, transaxle case, primary shaft gear and differential.
9. Install the secondary shaft gear and transaxle case then tighten to the specified torque.
Tightening torque: 37 - 52 N-m (3.8 - 5.3 m-kg, 27 - 38 ft-lb)
10. Measure the secondary shaft preload with the SST.
Preload: 0.2 - 0.4 N-m (2.0 - 4.0 cm-kg, 1.7 - 3.5 in-lb)
5th/Reverse Gear and Housing Parts
1. Assemble in the order shown in the image, referring to Assembly Note.
Assembly note
Primary shaft gear assembly and secondary shaft gear assembly
1. Install the primary shaft gear assembly and the secondary shaft gear assembly together.
Shift fork and shift rod assembly
1. Shift to 2nd gear and position the shift fork and shift rod assembly as shown.
2. Insert the spring seat and spring into the reverse lever shaft. install the steel ball, and place a scraper so that it contacts the steel ball.
3. With the edge of the control end against the scraper, when the control end is pushed in the direction of the arrow in the image so that the ball goes into the shaft, at the same time the rod will line up with the shift rod coupling hole in the clutch housing.
4. Set each clutch hub sleeve to the neutral position, and tap the shift rod from above so that the steel ball goes into the center groove (of the 3 grooves in the control end).
5. Pull the ball part of the control end forward so that the steel ball goes into the detent in the groove.
Crank lever assembly and crank lever shaft
NOTE: Use a new O-ring for the crank lever shaft.
1. Fit the crank lever between the change arm and the control end, and connect the crank lever shaft to the crank lever.
2. Align the pin holes of the crank lever shaft and the clutch housing, and insert the new pin.
5th/Reverse shift rod end, 5th/Reverse shift rod and clip
NOTE: The mark (indicated by the arrow in the image) and the shift rod end mounting bolt hole must be in the same direction.
1. Install the shift rod end (1) and the shift rod (2), and tighten the gate mounting bolt.
Reverse idler gear and reverse idler shaft
1. Install the reverse idler gear and the reverse idler shaft.
2. Attach the magnet to the clutch housing.
3. Align the end of the interlock sleeve with the control lever (indicated by the arrow), and, at the same time, face the reverse idler shaft screw hole in the direction shown in the image.
Clutch housing and transaxle case assembly
1. Apply a thin coat of sealant to the contact surfaces of the clutch housing and transaxle case, tighten the transaxle case installation bolts to the specified torque.
Tightening torque: 37 - 52 N-m (3.8 - 5.3 m-kg, 27 - 38 ft-lb)
2. Insert the SST through driveshaft hole.
Secondary 5th gear
1. Install the secondary 5th gear as shown.
Clutch hub assembly (5th/Reverse) and 5th/Reverse shift fork
1. Install the clutch hub assembly (5th/Reverse) and the 5th/Reverse shift fork together.
Locknut
1. Shift to 1st gear.
2. Lock the primary shaft with the SST.
3. Tighten new locknuts on the primary and secondary shafts.
Tightening torque: 128 - 196 N-m (13.0 - 20.0 m-kg, 94 - 145 ft-lb)
4. Stake the locknuts.